Predicting Filter Medium Performances in Chamber Filter Presses with Digital Twins Using Neural Network Technologies

Efficient solid–liquid separation is crucial in industries like mining, but traditional chamber filter presses depend heavily on manual monitoring, leading to inefficiencies, downtime, and resource wastage. This paper introduces a machine learning-powered digital twin framework to improve the operational flexibility and predictive control of a traditional chamber filter press. A key challenge addressed is the degradation of the filter medium due to repeated cycles and clogging, which reduces filtration efficiency. To solve this, a neural network-based predictive model was developed to forecast operational parameters, such as pressure and flow rates, under various conditions. This predictive capability allows for optimized filtration cycles, reduced downtime, and improved process efficiency. Additionally, the model predicts the filter medium’s lifespan, aiding in maintenance planning and resource sustainability. The digital twin framework enables seamless data exchange between filter press sensors and the predictive model, ensuring continuous updates to the training data and enhancing accuracy over time. Two neural network architectures, feedforward and recurrent, were evaluated. The recurrent neural network outperformed the feedforward model, demonstrating superior generalization. It achieved a relative L2-norm error of 5% for pressure and 9.3% for flow rate prediction on partially known data. For completely unknown data, the relative errors were 18.4% and 15.4%, respectively. Qualitative analysis showed strong alignment between predicted and measured data, with deviations within a confidence band of 8.2% for pressure and 4.8% for flow rate predictions. This work contributes an accurate predictive model, a new approach to predicting filter medium cycle impacts, and a real-time interface for model updates, ensuring adaptability to changing operational conditions.